Sand screen

ABSTRACT

A sand screen including a base pipe. A plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media about the base pipe. End rings engaging the filtration media and the base pipe.

BACKGROUND

In the drilling and completion industry, the formation of boreholes forthe purpose of recovering hydrocarbons necessarily is accompanied bysand. Sand control therefore is a significant concern for operators andmust be addressed in the downhole environment prior to its productionwith target fluids. This is because flowing sand is damaging toproduction equipment from the standpoint of erosion and further becauseit can adversely affect other equipment such as pumps, etc. Also notableis that the production of sand from the formation in which a boreholeexists will tend to enlarge the borehole and increase the probability ofcave ins, wash outs, etc., that would require remedial activity at notinsignificant cost both in actual dollars and in lost production time.

The art is therefore very concerned with sand control and has developeda plethora of types of sand screen and such to mitigate the problem. Inview of ever changing conditions and techniques however, the art isalways in need of and receptive to alternative arrangements.

BRIEF DESCRIPTION

A sand screen includes a base pipe; a plurality of individual segmentshaving complementary perimetrically interlocking shapes configured to benested together so as to limit relative movement among the elements andto form a tubular filtration media about the base pipe; end ringsengaging the filtration media and the base pipe.

A building component for a sand screen including a segment; a pluralityof merlons and a plurality of crenels at one longitudinal end of thesegment; a plurality of merlons and a plurality of crenels at anopposite longitudinal end of the segment, the merlons being configuredand dimensioned to be received in a crenel of a mating segment such thatadjacent side surfaces of each mated merlon will form a passagewaytherebetween.

A sand screen cartridge includes a plurality of individual segmentshaving complementary perimetrically interlocking shapes configured to benested together so as to limit relative movement among the elements andto form a tubular filtration media; end rings engaging the filtrationmedia and the base pipe; and a shroud spanning the filtration media andaffixed to the end rings.

A sand screen including a base pipe; a plurality of individual segmentshaving complementary perimetrically interlocking shapes configured to benested together so as to limit relative movement among the elements andto form a first tubular filtration media about the base pipe; anotherplurality of individual segments having complementary perimetricallyinterlocking shapes configured to be nested together so as to limitrelative movement among the elements and to form a second tubularfiltration media about the base pipe stacked adjacent the first tubularfiltration media; end rings engaging the first and second filtrationmedia and the base pipe; and a shroud spanning the first and secondfiltration medias.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 is a perspective view of a segment for a sand screen as disclosedherein;

FIG. 2 is a schematic view of the segment of FIG. 1 illustrating sidesurface angles of merlons;

FIG. 3 is another schematic view of the segment of FIG. 1 illustratingside surface angles of merlons;

FIG. 4 is a schematic view of a passageway through side surfaces ofadjacent merlons;

FIG. 5 is a schematic perspective view of a sand screen as disclosedherein; and

FIG. 6 is a schematic perspective view of a sand screen having multiplesand screen cartridges thereon.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

Referring to FIG. 1, a single segment 10 is illustrated. In thisembodiment, the segment is a closed annular form (e.g. a ring) but partannular forms are also contemplated. In some embodiments the segmentsare constructed of hard erosion resistant material and may be a ceramicmaterial. Other hard metal or plastic is also contemplated. If indeed aceramic material is selected, the material may comprise for exampleSintered Boron Carbide, Silicon Carbide, etc.

Still referring to FIG. 1, segment 10 is castellated on bothlongitudinal ends 12 and 14, the axis defining longitudinal in thiscase. The castellation in direction 12 is a mirror image longitudinallyfrom the castellation in direction 14. It is to be understood however,that it is not required that the castellations be mirrored end to endbut to be appreciated that the castellation may be different in shape,different in register relative to castellations on the opposite end,etc. Rather what is important is that a plurality of the segments needto nest together to form a tubular structure that presents pathways forfluid to move therethrough. This can be accomplished with mirror imagedconfiguration as illustrated or with more complexity with otherconfigurations. An advantage of the segments being mirror images on eachend or at least mirrored shapes on both ends is that the plurality ofsegments may be identical to each other allowing for easy assembly intothe tubular form without need to ensure the right segments are nestingwith the right other segments. Rather each will nest identically withthe next. It should also be appreciated that although a cylindricalshape of the segments is illustrated, other tubular shapes are alsocontemplated.

Still referring to FIG. 1, standoffs 16 are illustrated at an insidesurface 18 of the segment 10. These may be of any number but likely notfewer than three and function to provide a drainage gap between theplurality of segments and a basepipe around which they will bepositioned when the sand screen is assembled (see FIG. 4). In otherwords, the standoffs 16 will abut an outside surface of the basepipe andensure that the inside surface 18 of the plurality of segments 10 willnot contact the outside surface of the basepipe.

Also to be noted though relatively small in FIG. 1 (more easily seen inFIGS. 2 and 3) is a keying feature such as an offset 20, of which thereare two in each crenel 22 of the segment 10 as illustrated. It is to beunderstood that this is but one embodiment of a configuration to ensurethat the nested segments 10 (creating a filtration media 11) registerproperly with one another to ensure that the intended fluid passagewayswill be substantially uniformly distributed. Other offset or key andkeyway type arrangements may be substituted while achieving the sameresults. Barring a configuration providing for this registrationfunction, the segments might turn relative to one another therebycreating a larger passageway on one side of a castellation that intendedand a smaller one on the other side of the same castellation. This wouldreduce functionality of the sand screen.

Referring to FIGS. 1, 2 and 3 together enlarged views will improveunderstanding of the features mentioned and facilitate description ofthe shape of the castellations themselves. In one embodiment of thesegment 10 the castellations comprise a number of trapezoidal merlons 24interspaced by crenels 22. In some embodiments, like the oneillustrated, the merlons and crenels are sized to fit within each otheror nest. Specifically, a crown surface 26 is configured to fit withcrenel base surface 28, between the offsets 20. During construction ofthe sand screen, the crown surfaces 26 of each of the segments 10 to beused are coated with a resilient sealer such as a rubber or similar andwill seal with surface 28. At the sides of the merlons however, thesurfaces 30, it is intended that passageways 32 be formed, see FIG. 4.For this purpose, the side surfaces 30 are dimensioned and configured tobe spaced apart from an adjacent merlon when the segments are nestedtogether. This is accomplished in part by the offsets 20 and in part bythe dimensions of the merlon itself relative to the dimensions of thecrenel. The crenel 22 is slightly wider than the merlon that extendsthereinto when nested. Further, in some embodiments it is desirable tohave surfaces 30 when nested be parallel to each other, although it iscertainly possible and in some cases could be desirable to havediverging or converging passageways simply by adjusting the angle of thesurfaces 30. In order to effect a parallel result, the actual radialangle of the surface 30 relative to a radial line drawn from the axis ofthe segment is about 1 degree different than the radial line resultingin a narrower merlon toward the inner surface of the segment than at theouter surface of the segment. A longitudinal angle of surface 30 of thetrapezoid of merlon 24 is selectable as desired and in some embodimentsranges from about 0.5 degrees to about 10 degrees. The greater theangle, the longer the particular flow passageway. For some iterations ofthe segments 10, the greater angle may provide for more flow area but itis also to be appreciated that a smaller angle coupled with more merlons24 may provide an even greater total flow area even though theindividual flow passageways would be shorter in length.

Referring to FIG. 5, an assembled sand screen comprising a plurality ofsegments nested together (the filtration media 11) is illustrated. Endrings 34 are also illustrated that in some embodiments are rubbery typematerial and configured to mate with a last of a plurality of segmentson an axial end of a stack of such segments (filtration media 11) asshown. The end rings 34 have an inside diameter that is close to anoutside diameter of a base pipe 36 to which they are mated. In someembodiments there will also be a metal backup 38 that may be welded tothe base pipe 36 to help retain the other components in place. Andfinally, an optional shroud 40 is shown radially outwardly placed of thestacked segments and welded to the metal backups 38 and/or affixed tothe end rings 34 by for example swaging. In the first instance, becausea base pipe 36 is included, the welding of the shroud to the backups 38will keep it in place. In the second instance however, while theaffixation to the end rings 34 may be used with a basepipe, it furtherfacilitates the construction of a sand screen cartridge 39 comprisingthe plurality of segments 10 (filtration media 11), the end rings 34 andthe shroud 40 but without the base pipe. Embodiments directed tocartridges may optionally also contain backups 38 welded to the shroud40. The cartridge embodiments allow for an additional marketingopportunity as the sand screen cartridge may be sold and transportedwithout a basepipe and thence may be installed on a base pipe at thewell site or some other location that is convenient.

In another embodiment, referring to FIG. 6, the shroud 40 is a unifyingcomponent for a number of individual cartridges 39. More specifically,the filtration media 11 and end rings may be assembled in, for exampleonly, 18 inch increments and then other of that same construction (oreven other lengths) stacked adjacent each other on a base pipe, all ofwhich are spanned by a single shroud. This would provide a more flexiblesand screen and may simplify shipping since the sand screen cartridgeswould be small and relatively light weight when compared to a completesand screen including the base pipe. It also would allow an operator tomake a sand screen as long as is needed for the specific application bystacking cartridge segments to the desired length and cutting orextending the shroud to span them.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Further, it should further be noted that the terms “first,”“second,” and the like herein do not denote any order, quantity, orimportance, but rather are used to distinguish one element from another.The modifier “about” used in connection with a quantity is inclusive ofthe stated value and has the meaning dictated by the context (e.g., itincludes the degree of error associated with measurement of theparticular quantity).

The teachings of the present disclosure may be used in a variety of welloperations. These operations may involve using one or more treatmentagents to treat a formation, the fluids resident in a formation, awellbore, and/or equipment in the wellbore, such as production tubing.The treatment agents may be in the form of liquids, gases, solids,semi-solids, and mixtures thereof. Illustrative treatment agentsinclude, but are not limited to, fracturing fluids, acids, steam, water,brine, anti-corrosion agents, cement, permeability modifiers, drillingmuds, emulsifiers, demulsifiers, tracers, flow improvers etc.Illustrative well operations include, but are not limited to, hydraulicfracturing, stimulation, tracer injection, cleaning, acidizing, steaminjection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplaryembodiment or embodiments, it will be understood by those skilled in theart that various changes may be made and equivalents may be substitutedfor elements thereof without departing from the scope of the invention.In addition, many modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodiment disclosedas the best mode contemplated for carrying out this invention, but thatthe invention will include all embodiments falling within the scope ofthe claims. Also, in the drawings and the description, there have beendisclosed exemplary embodiments of the invention and, although specificterms may have been employed, they are unless otherwise stated used in ageneric and descriptive sense only and not for purposes of limitation,the scope of the invention therefore not being so limited.

What is claimed is:
 1. A sand screen comprising: a base pipe; aplurality of individual segments having complementary perimetricallyinterlocking shapes configured to be nested together so as to limitrelative movement among the elements and to form a tubular filtrationmedia about the base pipe; end rings engaging the filtration media andthe base pipe.
 2. A sand screen as claimed in claim 1 wherein theplurality of segments include offsets to space certain faces of theplurality of elements from mating faces of the plurality of elements tocreate radial fluid passageways through the filtration media.
 3. A sandscreen as claimed in claim 1 wherein the plurality of segments furtherinclude standoffs to space the segments from the base pipe.
 3. A sandscreen as claimed in claim 1 wherein the plurality of segments arerings.
 4. A sand screen as claimed in claim 3 wherein the rings arecastellated by merlons and crenels.
 5. A sand screen as claimed in claim4 wherein the merlons include side surfaces that are angled at about 1degree less than an angle represented by a radial line from an axis ofthe rings.
 6. A sand screen as claimed in claim 5 wherein the sidesurfaces are angled to so that mating side surfaces of adjacent merlonsare parallel therewith.
 7. A sand screen as claimed in claim 4 whereinthe merlons include side surfaces that when nested with mating sidesurfaces of adjacent merlons produce one of narrowing pathways from anouter surface of the filtration media to an inner surface of thefiltration media or widening pathways from an outer surface of thefiltration media to an inner surface of the filtration media.
 8. A sandscreen as claimed in claim 4 wherein each merlon includes a side surfaceat an angle to a line parallel to an axis of the ring of about 0.5 toabout 15 degrees.
 9. A sand screen as claimed in claim 8 wherein anopposite side surface of the merlon has a mirror imaged angle.
 10. Asand screen as claimed in claim 4 further comprising a sealing materialdisposed upon a crown of each merlon.
 11. A sand screen as claimed inclaim 10 wherein the sealing material creates a seal between the crownof each merlon and a base of each crenel of a mating ring.
 12. A sandscreen as claimed in claim 11 wherein the sealing material is a polymer.13. A sand screen as claimed in claim 1 wherein the plurality of hardsegments comprise a highly erosion resistant material.
 14. A sand screenas claimed in claim 13 wherein the material comprises ceramic.
 15. Asand screen as claimed in claim 14 wherein the ceramic comprisesSintered Boron Carbide and/or Silicon Carbide.
 16. A building componentfor a sand screen comprising: a segment; a plurality of merlons and aplurality of crenels at one longitudinal end of the segment; a pluralityof merlons and a plurality of crenels at an opposite longitudinal end ofthe segment, the merlons being configured and dimensioned to be receivedin a crenel of a mating segment such that adjacent side surfaces of eachmated merlon will form a passageway therebetween.
 17. A buildingcomponent for a sand screen as claimed in claim 16 wherein the segmentis annular.
 18. A building component for a sand screen as claimed inclaim 16 wherein the segment includes a keying feature to ensureadjacent segments when stacked to form a filtration media areregistered.
 19. A sand screen cartridge comprising: a plurality ofindividual segments having complementary perimetrically interlockingshapes configured to be nested together so as to limit relative movementamong the elements and to form a tubular filtration media; end ringsengaging the filtration media and the base pipe; and a shroud spanningthe filtration media and affixed to the end rings.
 20. A sand screencomprising: a base pipe; a plurality of individual segments havingcomplementary perimetrically interlocking shapes configured to be nestedtogether so as to limit relative movement among the elements and to forma first tubular filtration media about the base pipe; another pluralityof individual segments having complementary perimetrically interlockingshapes configured to be nested together so as to limit relative movementamong the elements and to form a second tubular filtration media aboutthe base pipe stacked adjacent the first tubular filtration media; endrings engaging the first and second filtration media and the base pipe;and a shroud spanning the first and second filtration medias.